Knockdown bed foundation

ABSTRACT

The field of the present invention pertains to foundations or bedsteads for supporting mattresses. More particularly, the present invention relates to foundations that can be knocked down and reassembled by the end user. The present invention when reassembled presents a visual impression to the end user that can look like a conventional, fixed assembly foundation. The invention further provides for a method for assembling the present knockdown foundation devices.

BACKGROUND OF THE INVENTION

(1). Field of the Invention

The field of the present invention pertains to foundations or bedsteads for supporting mattresses. More particularly, the present invention relates to foundations that can be knocked down and reassembled by the end user. The present invention when reassembled presents a visual impression to the end user that can look like a conventional, fixed assembly foundation. The invention further provides for a method for assembling the knockdown foundation devices.

(2). Description of the Related Art, Including Information Disclosed Under 37 CFR 1.97 & 1.98

The prior art has several attempts at making a knockdown foundation. However, the prior art has failed to disclose a combination of elements that can not only be knocked down and reassembled, but also can provide the desired quality look of assembled foundations.

For example, U.S. Pat. No. 5,564,140 to Shoenhair et alia, discloses a collapsible foundation that comprises a combination of a bed frame and a bed foundation. A number of mattress support panels are clipped to foundation side rails and end rails, which are in turn, pinned to the bed frame. One aligns the rails through screws and brackets. The end result bears no resemblance to the look of a conventional bed foundation.

Another approach is shown in U.S. Pat. No. 6,832,397 to Gaboury et alia. Here a knockdown bed foundation is comprised of blow molded plastic pieces. The foundation again uses mattress panels combined with foundation side rails and end rails. Dovetail joints are used to join the parallel side rails by means of a number of transverse rails. Again, the end result bears no resemblance to the look of a conventional bed foundation.

BRIEF SUMMARY OF THE INVENTION

The present invention relates to a foundations or bedsteads for supporting mattresses. More particularly, the present invention relates to foundations that can be knocked down and reassembled by the end user. The present invention when reassembled presents a look to the end user that can look like a conventional assembled foundation. The invention further provides for a method for assembly the knockdown foundation devices.

The present invention comprises a knockdown bed foundation (10) that can support a mattress. As seen in FIG. 2, the combination of elements for this foundation includes a pair of side rails ((20) and (30)) that form opposing supportive sides of the foundation (each side rail having two ends, respectively (22) and (24) as well as (32) and (34)) and a pair of end rails ((40) and (50)) that form opposing head and foot supportive ends of the foundation (each end rail also having two ends, respectively (42) and (44) as well as (52) and (54)). It also includes a plurality of rail connecting means (60). Each connecting means is located in part on a side rail and in part on an end rail. Each connecting means is dimensioned and configured to hold one end of one of the side rails and one end of one of the end rails in a fixed angular relationship. Finally the combination includes a resealable foundation cover (70) that has an open position and a closed position. The cover has side surfaces (72), a top surface (74), and a bottom (76) surface (both internal and external). Moreover, for the assembled foundation the cover is in the closed position, a position that is dimensioned and configured so as to surround the assembled combination of the side rails, the end rails, the connecting means, and the six planes formed by this combination.

The present invention also comprises a method for assembling a knockdown bed foundation that can support a mattress. The steps of this method include first selecting a combination of elements as described above. Second, one connects one end of one of the side rails to one end of one of the end rails by means of the respective connecting means, thereby forming an assembled rail combination of rails. Next, one opens the resealable foundation cover so as to expose substantially the internal surface. The assembled rail combination is then placed onto the exposed internal surface of the cover such that the dimensions of the assembled rail combination are aligned with the dimensions of the corresponding internal surface of the cover. Finally, one closes the cover such that only the external surface of the cover is exposed, thereby surrounding the assembled rail combination.

An object of the invention is to provide a bed foundation that has the look of a quality, fixed assembly bed foundation while being a knockdown foundation.

A second object of the invention is to provide a bed foundation that can be assembled without any tools.

A third object of the invention is to provide a bed foundation that can be disassembled into a package that can be shipped through conventional ground delivery services such as FedEx Ground or United Parcel Service.

A fourth object of the invention is to provide a bed foundation that is marked for ease of assembly and to prevent mis-assembly.

A fifth object of the invention is to provide a bed foundation that will stay assembled even if oriented in a non-use position.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of a preferred embodiment of the present invention showing the claimed element in a closed position.

FIG. 2 is a perspective view of a preferred embodiment of the present invention showing the claimed element in an open position.

FIG. 3 is a plan and sectional view of the FIG. 1 device.

FIG. 4 is a detailed view of the rail connections of the FIG. 1 device.

FIG. 5 is a detailed view of the corner rail connections of the FIG. 1 device.

DETAILED DESCRIPTION OF THE INVENTION

A preferred embodiment is shown in FIGUREs. In addition to the elements described above, the foundation also comprises at least one transverse rail (80). Each transverse rail has two ends, respectively (82) and (84). Each end is dimensioned and configured to connect releasably to a respective side rail. This preferred embodiment also comprises at least one intermediate longitudinal rail (90). Each intermediate longitudinal rail has two ends, respectively (92) and (94). Each end is dimensioned and configured to connect releasably to a respective end rail. The rails can be made from a variety of conventional materials, including wood, engineered wood products, plastics, metals, alloys, or any combination thereof.

A preferred method for connecting a side rail to an end rail is through a rail connecting means comprising a pin (62) and interlocking hole ((64) and (66)) means. Examples of such means are disclosed in U.S. Pat. No. 5,709,500, and are shown in FIG. 5.

In certain preferred embodiments, the foundation cover (70) has a resealable means (such as a zipper) that extends along three of the side planes of the assembled combination. Most preferably this zipper is located about midway within the longitudinal axis of the side planes. Also, the foundation cover may be dimensioned and configured such that the internal surface of the cover can be substantially exposed and the assembled rail combination can be placed onto that internal surface prior to the cover being sealed (as shown in FIG. 2) so as to surround the assembled combination. {

Fire resistance can be an important factor in a consumer selecting a bed foundation. Therefore, the foundation cover can also comprise fire-resistant material on the external surface. In some cases, one can limit such materials to all of the external side and bottom surfaces, but on the top surface such fire-resistant material extends inward from the side edge only a distance sufficient to be covered by a mattress placed on top of the foundation (as shown by the dotted line in FIG. 1). This provides sufficient protection while reducing the cost of materials.

Besides fire resistance, the cover can also function to keep the assembled foundation together. As shown in FIG. 3, the foundation cover can be dimensioned and configured such that when closed each pin (62) cannot be displaced from its respective interlocking hole means (64) and (66). Moreover, the resealable foundation cover can be dimensioned and configured such that, when closed, each transverse rail cannot be displaced from the side rail.

One way to connect the side rail and transverse rail is shown in FIG. 4. Each side rail has a female slot, such as (26), for locating a respective male end, such as (82) of each transverse rail that connects therewith. Each slot on the side rail is dimensioned and configured to receive snugly the respective male transverse rail end. Likewise, in preferred embodiments, each intermediate rail end, such as (92) connects to a respective end rail by means of a combination of a male end on each intermediate rail end and a female slot, such as (46) on each respective end rail. Again, each slot on the end rail is dimensioned and configured to receive snugly the respective transverse rail end.

If further compactness is desired for the present invention, then one can use side rails or end rails that are more than one piece held together by a conventional connecting means (such as the pin and interlocking hole means described above) or a conventional hinging or folding means.

To assist the end user in assembling the foundation in the proper manner the first time, preferred embodiments of the present invention have certain designations that aid in assembly. More particularly, each side rail and each end rail have separate designations, such as (28) and (48), at each end such that the respective side rail end and end rail end that are joined together have a distinct and matching designation (as shown in FIG. 5). Moreover, each side rail and each end rail can be designated (28) and (48) so as to indicate the top and bottom orientation (again as shown in FIG. 5).

The ordinarily skilled artisan can appreciate that the present invention can incorporate any number of the preferred features described above.

All publications or unpublished patent applications mentioned herein are hereby incorporated by reference thereto.

Other embodiments of the present invention are not presented here which are obvious to those of ordinary skill in the art, now or during the term of any patent issuing from this patent specification, and thus, are within the spirit and scope of the present invention. 

1. A knockdown bed foundation that can support a mattress comprising: a) a pair of side rails that form opposing supportive sides of the foundation, each side rail having two ends; b) a pair of end rails that form opposing head and foot supportive ends of the foundation, each end rail having two ends: c) a plurality of rail connecting means, each connecting means located in part on a side rail and in part on an end rail, each connecting means being dimensioned and configured to hold one end of one of the side rails and one end of one of the end rails in a fixed angular relationship; and d) a resealable foundation cover with an open position and a closed position, the cover having side, top, and bottom surfaces, both internal and external, and the cover being in the closed position, a position dimensioned and configured so as to surround the assembled combination of the side rails, the end rails, the connecting means, and the six planes formed by this combination.
 2. The bed foundation of claim 1 also comprising at least one transverse rail, each transverse rail having two ends, each end being dimensioned and configured to connect releasably to a respective side rail.
 3. The bed foundation of claim 1 also comprising at least one intermediate longitudinal rail, each intermediate longitudinal rail having two ends, each end being dimensioned and configured to connect releasably to a respective end rail.
 4. The bed foundation of claim 1 also comprising: a) at least one intermediate longitudinal rail, each intermediate longitudinal rail having two ends, each end being connected dimensioned and configured to connect releasably to a respective end rail; and b) at least one transverse rail, each transverse rail having two ends, each end being connected dimensioned and configured to connect releasably to a respective side rail and to each intermediate rail.
 5. The bed foundation of claim 1 wherein the cover has a resealable means that extends along three of the side planes of the assembled combination.
 6. The bed foundation of claim 1 wherein the cover is dimensioned and configured such that the internal surface of the cover can be substantially exposed and the assembled rail combination can be placed onto that internal surface prior to the cover being sealed so as to surround the assembled combination
 7. The bed foundation of claim 2 wherein each side rail has a female slot for locating a respective male end of each transverse rail that connects therewith, each slot being dimensioned and configured to receive snugly the respective male transverse rail end.
 8. The bed foundation of claim 3 wherein each intermediate rail end connects to a respective end rail by means of a combination of a male end on each intermediate rail end and a female slot on each respective end rail, each slot being dimensioned and configured to receive snugly the respective transverse rail end.
 9. The bed foundation of claim 4 wherein: each side rail has a female slot for locating a respective male end of each transverse rail that connects therewith, each slot being dimensioned and configured to receive snugly the respective male transverse rail end; and each intermediate rail end connects to a respective end rail by means of a combination of a male end on each intermediate rail end and a female slot on each respective end rail, each slot being dimensioned and configured to receive snugly the respective transverse rail end.
 10. The bed foundation of claim 1 wherein each rail connecting means comprises a pin and interlocking hole means.
 11. The bed foundation of claim 1 wherein each side rail is comprised of at least two parts that can be releaseably interconnected by a connecting means so as to form each side rail.
 12. The bed foundation of claim 1 wherein each end rail is comprised of at least two parts that can be releaseably interconnected by a connecting means so as to form each end rail.
 13. The bed foundation of claim 1 wherein the resealable foundation cover also comprises fire-resistant material on the external surface.
 14. The bed foundation of claim 13 wherein the resealable foundation cover has fire-resistant material on all of the external side and bottom surfaces, but on the top surface such fire-resistant material extends inward from the side edge only a distance sufficient to be covered by a mattress placed on top of the foundation.
 15. The bed foundation of claim 10 wherein the resealable foundation cover is dimensioned and configured such that when closed each pin cannot be displaced from its respective pair of interlocking holes.
 16. The bed foundation of claim 2 wherein the resealable foundation cover is dimensioned and configured such that when closed each transverse rail cannot be displaced from the side rail.
 17. The bed foundation of claim 1 wherein each side rail and each end rail is designated at each end such that the respective side rail end and end rail end that are joined together have a distinct and matching designation.
 18. The bed foundation of claim 1 wherein each side rail and each end rail is designated so as to indicate the top and bottom orientation.
 19. A method of assembling a knockdown bed foundation that can support a mattress comprising: a) selecting the following elements: i) a pair of side rails that form opposing supportive sides of the foundation, each side rail having two ends; ii) a pair of end rails that form opposing head and foot supportive ends of the foundation, each end rail having two ends: iii) a plurality of rail connecting means, each connecting means being located in part on a side rail and in part on an end rail, each rail connecting means being dimensioned and configured to hold one end of one of the side rails and one end of one of the end rails in a fixed angular relationship; and iv) a resealable foundation cover with an open position and a closed position, said cover having side, top, and bottom surfaces, both internal and external, the cover being dimensioned and configured so as to surround the assembled combination of the side rails, the end rails, the connecting means, and the six planes formed by this combination; b) connecting each end of one of the side rails to one end of one of the end rails by means of the respective connecting means, thereby forming an assembled rail combination of rails; c) opening the resealable foundation cover so as to expose substantially the internal surface; d) placing the assembled rail combination onto the exposed internal surface of the cover such that the dimensions of the assembled rail combination aligned with the dimensions of the corresponding internal surface of the cover; and e) closing the cover such that only the external surface of the cover is exposed, thereby surrounding the assembled rail combination. 